Prelubricated stock sheet and method and system for making the same

ABSTRACT

A pre-lubricated stock sheet and a method and system for making the same are described. The pre-lubricated stock is generally in a coil wound form. The stock sheet can have opposing first and second sheet surfaces joined together by opposing side edges and opposing ends. Typically, the first and second sheet surfaces are substantially smooth and planar, wherein the sheet has 3 mg/foot 2 /side to about 200 mg/foot 2 /side of a solid lubricant having a melting temperature from about 80 to 212 degrees Fahrenheit. Moreover, the opposing side edges usually are substantially free of the solid lubricant. In some configurations, the stock sheet is an aluminum stock sheet, more particularly an aluminum can stock sheet. Furthermore, the lubricant can be in some configurations a food grade lubricant, that is qualifies a low volatile organic compound under one or more of municipal, state and federal governing authorities.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefits of U.S. ProvisionalApplication Ser. Nos. 62/211,180, filed Aug. 28, 2015, 62/213,376, filedSep. 2, 2015, 62/214,540, filed Sep. 4, 2015, and 62/219,485, filed Sep.16, 2015, each entitled “Method and System for Applying Lube to AluminumSheet”, each of which is incorporated herein by this reference in itsentirety.

BACKGROUND

A stamping press is a machine tool used to shape or cut a sheet intodesired objects by deforming it with a die. A press typically has abolster plate, die, and a ram. The bolster plate (or bed) is a largeblock of metal upon which the bottom portion of the die is clamped. Thebolster plate is stationary. Stamping presses can be subdivided intomechanically driven presses and hydraulically driven presses. Typically,presses are electronically linked (with a programmable logic controller)to an automatic feeder which feeds metal raw material through the die.The raw material is fed into the automatic feeder after it has beenunrolled from a coil and put through a straightener.

To avoid damage to the sheet and die when subjected to the substantialpressures encountered in the stamping press, it is common for thestamping press operator to apply a lubricant material to the sheetbefore stamping. The lubricant has been applied by many techniques,including a sprayer or roll coater. These techniques apply the lubricantin a layer of non-uniform thickness, which can cause problems duringstamping.

SUMMARY

The various aspects, embodiments, and configurations of the presentdisclosure address these and other needs. The disclosure is directed toa method and system for applying lubricant to a stock sheet to form alubricated stock sheet before the further processing of the stock sheet,such as by stamping. In some embodiments, the lubricant is applied tothe stock sheet by the stock sheet manufacturer before shipment to astamping press facility.

According to the disclosure, a solid lubricant is melted and applied asa liquid to the stock sheet in a desired consistency and thickness. Thelubricant, which has a melting point above room (ambient) temperature,solidifies at ambient temperature before coiling and shipment of thestock sheet to the stamper and/or former, such as a container orautomotive manufacturer.

The stock sheet can be any metal comprising a metal or a mixture ofmetals. Examples include steel sheet, aluminum sheet, copper sheet, andthe like. The metal sheet can be used not only in the fabrication ofcontainers but also in the fabrication of automotive parts andinnumerable other applications.

The stock sheet can be a nonmetal material, such as plastic or glasssheet.

The stock sheet can be steel, stainless steel, copper, tin, nickel,gold, platinum, rhodium, aluminum, an organic polymeric material, ametal, an alloyed metal, or a combination thereof. The stock sheet canbe selected from the group consisting essentially of steel, stainlesssteel, copper, tin, nickel, gold, platinum, rhodium, aluminum, anorganic polymeric material, a metal, an alloyed metal, or a combinationthereof.

The stock sheet may or may not be coil wound. In some embodiments, thecoil wound sheet can be an automotive sheet stock. Generally, theautomotive sheet stock is one of 3000 series, 5000 series, 6000 series,7000 series or other aluminum or steel alloy. In some embodiments, thecoil wound sheet can be tab stock for a container.

The lubricant is normally a solid at ambient temperature. The solidlubricant can have a melting temperature from about 80 to 212 degreesFahrenheit, more commonly, more commonly from about 100 to 200 degreesFahrenheit, and even more commonly from about 140 to 195 degreesFahrenheit. In some embodiments, the solid lubricant can be a food gradelubricant. The solid lubricant can commonly be one or more of a NSF,Kosher or Halal approved food grade lubricant. Generally, the solidlubricant can be one of dioctyl sulfosuccinate,1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl) imide, dioctylsebacate, bis(2-ethylhexyl) sebacate, sebacic acid di(2-ethylhexyl)ester, hydrotreated heavy naphthenic petroleum distillates, alkeneshaving a carbon chain length greater than ten, and poly-α-olefin,petrolatum, and mixtures thereof. Typically, the solid lubricate is aFDA approved lubricant per 21 CFR 178.3910 Paragraph (b). In someembodiments, the solid lubricant can qualify as a low volatile organiccompound under one or more of municipal, state and federal governingauthorities.

The lubricant can be applied precisely to selected areas of the sheet.For example, the opposing side edges of the sheet can be substantiallyfree of the solid lubricant while the upper and lower surfaces of eachof the first (upper) and second (lower) sheet surfaces contain asubstantially continuous and uniform lubricant layer.

In some applications, the first (upper) and second (lower) surfaces,respectively, can have first and second sheet surface areas. Moretypically, from about 99 to 100% of the first and second sheet surfaceareas are in contact with the solid lubricant.

Each of the first and second sheet surfaces can commonly have from about3 mg/foot²/side to about 200 mg/foot²/side of the lubricant, morecommonly about 5 mg/foot²/side to about 110 mg/foot²/side of thelubricant or even more commonly about 60 mg/foot²/side to about 90mg/foot²/side of the lubricant. In some embodiments, each of the upperand lower surfaces of the sheet can generally have about 150±10 mg/foot²of lubricant, more generally about 100±10 mg/foot² of lubricant, evenmore generally about 80±10 mg/foot² of lubricant, and even moregenerally about 90±10 mg/foot² of lubricant.

The lubricant is applied by a device having one or more pairs ofapplicators, with the applicators in each of the one or more pairs ofapplicators applying lubricant to one of the opposing first and secondstock sheet surfaces. Each applicator can include: a porous applicatorelement commonly having first and second porous element surfaces; aperforated applicator element generally having first and secondperforated element surfaces, with the first perforated element surfacetypically being in contact with the second porous element surface; and aliquid-dispensing element, with the liquid-dispensing element generallydispensing a liquid lubricant. The dispensed liquid lubricant cancontact the second perforated element surface. The device can also havea pressure-adjusting element, one or more heating elements, and anenclosure. The applicators and heating elements can be contained withthe enclosure. The device can also include a lubricant-containing vesselin fluid communication with each of the liquid-dispensing elements ofthe applicators.

Each applicator can have an applicator axis. The liquid-dispensingelement can be positioned along the applicator axis. The first porouselement surface can be the outer surface of each applicator of the oneor more applicators. The second perforated element surface can be theinner surface of each of applicator.

The enclosure can further include a sheet inlet and a sheet outletconfigured for the stock sheet to traverse the enclosure. The sheet cantraverse midway between each pair of the applicators. The enclosure canbe insulated, non-insulated, or a combination thereof.

The pairs of applicators can be arranged in series (with respect to aselected portion of the stock sheet surface) or parallel (with respectto a width of the stock sheet surface). The pairs of applicators caninclude from about two to about three pairs of applicators. About two toabout six pairs of applicators can be arranged in series.

The one or more heating elements can be positioned between the enclosureand pairs of applicators. The one or more heating elements can bepositioned symmetrically about the pairs of applicators and providesufficient thermal energy to the applicators to maintain a temperaturewithin the enclosure of from about 80 to 212 degrees Fahrenheit, morecommonly from about 100 to 200 degrees Fahrenheit, and even morecommonly from about 140 to 195 degrees Fahrenheit. The one or moreheating elements can be one of an electrical resistance heating element,a hot water radiant heating element, a stream radiant heating element, ahigh-pressure steam radiant heating element, a super-critical steamradiant heating element, an infrared heating element, or a hot oilradiant heating element.

The perforated applicator element can be a metallic material, apolymeric material, or a combination thereof. When a metallic materialis used, the perforated applicator element can be steel, stainlesssteel, aluminum, stainless steel, or brass. The perforated applicatorelement can have a plurality of apertures, a plurality of channels, or acombination thereof substantially uniformly distributed over theperforated applicator element surface area. Furthermore, the pluralityof apertures, the plurality of channels, or the combination thereof aresufficiently sized such that lubricant is uniformly distributed to theporous applicator element and is not retrained by perforated applicatorelement.

The porous applicator element can comprise one of a textile material, anorganic polymeric material, an inorganic polymeric material, or acombination thereof. Furthermore, the porous applicator element cancomprise one of a felt, a non-woven material, a solid foam material, asponge material, or a fabric. Moreover, the porous applicator elementcan be permeable, porous, or both porous and permeable. Usually, theporous applicator element can have a wall thickness from about 1/16 toabout ½ and more commonly from about ⅛ to about ¼ of an inch.

Each adjacent pair of applicators can have first and second applicatoraxes aligned in parallel, with a distance between them. First and secondouter surfaces of the applicators forming each pair of applicators aregenerally separated by a distance sufficient to accept the stock sheet.Typically, a pressure-adjusting element can increase and/or decrease thepressure of the first second outer surfaces of the applicators on thestock sheet positioned between them.

The pressure-adjusting element can increase and/or decrease the pressureof the first and second outer surfaces of applicators on the stock sheetpositioned between them. It can be appreciated that thepressure-adjusting element can include one of an electromechanicaldevice, a solenoid, a pneumatic device, or a combination thereof. Thepressure-adjusting element can be contained within the enclosure,external to the enclosure, or partially contained within the enclosureand partially contained external to the enclosure.

The device can include one or more temperature sensing elements. Theenclosure can have a void volume having a void volume temperature, wherethe temperature sensing elements can determine the void volumetemperature. The temperature sensing elements can be contained within orlocated outside of the enclosure. Some of the temperature sensingelements can be configured external to the enclosure while others arecontained within the enclosure.

The lubricant-containing vessel can be a heated vessel containing aliquefied lubricant. Generally, the lubricant-containing vessel isheated to a temperature greater than the ambient temperature to liquefythe solid lubricant.

The device can include a pressurizing element. Generally, thepressurizing element conveys the liquefied lubricant from thelubricant-containing vessel to the liquid-dispensing elements of each ofthe applicators. The pressurizing element can pressurize the headspaceof the lubricant-containing vessel. The pressure of the pressurizedheadspace can be sufficient to force the liquefied lubricant fromlubricant-containing vessel to the liquid dispensing elements.Generally, the liquefied lubricant is convey to the liquid dispensingelement without the need to pump the liquefied lubricant from thelubricant-containing vessel. This can be, for example, a pressurizedhead space in a container in the absence of a pump to avoid lubricantsolidification and pump malfunction.

In operation, a stock sheet is input into the device and contacted withone or more pairs of applicators to form opposing lubricated layers onthe first and second stock sheet surfaces. The lubricated stock sheetcan be wound coil into a roll of the lubricated stock sheet. Theliquefied lubricant is generally applied at a temperature greater thanthe ambient temperature. Typically, the contacting step occurs at atemperature from about 80 to 212 degrees Fahrenheit, more commonly, morecommonly from about 100 to 200 degrees Fahrenheit, and even morecommonly from about 140 to 195 degrees Fahrenheit. While the lubricantis typically a solid lubricant at ambient temperature, it is commonlydeposited (on the interior areas of the stock sheet) in a liquefiedstate but the opposing stock sheet edges are commonly substantially freeof the liquefied lubricant.

The device can flow the liquefied lubricant from a lubricant-containingvessel to a liquid-dispensing element; dispense, from theliquid-dispending element, the liquefied lubricant to a perforatedapplicator element having first and second perforated element surfaces,and contact the first porous element surface with the stock sheetsurface to deposit the liquefied lubricant on the stock sheet. Theperforated applicator element can typically be in fluid communicationwith a porous applicator element having first and second porous elementsurfaces. The liquefied lubricant can flow from the first perforatedelement surface to the second porous element surface and from the secondporous element surface to the first porous element surface.

In some embodiments, the stock sheet can commonly be contacted with eachpair of the one or more pairs of applicators at a rate of about 50 toabout 6,000 feet per minute, more commonly at a rate of about 100 toabout 2,000 feet per minute, or even more commonly at a rate of about400 to about 700 feet per minute.

The present disclosure can provide a number of advantages depending onthe particular configuration. The method and system of this disclosurecan provide a substantially, continuous, consistent and uniformlubricant layer thickness over the upper and lower surfaces of the stocksheet. The method and system can provide highly controlled lubricantapplication in amount and coverage. Sufficient lubricant can be appliedby the stock sheet manufacturer to avoid the stamping press operatorfrom needing to deposit the lubricant. The substantially continuous andconsistent lubricant layer thickness over the area of the stock sheetcan provide better results in stamping operations (such as tabformation) than other lubrication techniques and yield longer die life.The disclosed method also allows no lubricant to be used at the stamperpress and to decrease the volatile organic compound levels at theconversion press to decreased and/or eliminated. The lubricant alsoprotects the die and reduces and/or eliminates fines produced during theforming/stamping process. The reduction of fines decreases and/oreliminated sharp edge formation and wear on the die tool.

These and other advantages will be apparent from the disclosure of theaspects, embodiments, and configurations contained herein.

It can be appreciated that the perforated applicator element and theporous applicator element can have any shape. In some embodiments, theperforated applicator element and the porous applicator element can havea cylindrical shape. In some embodiments, the perforated applicatorelement and the porous applicator element can have elliptical shapes.

It is to be noted that the term “a” or “an” entity refers to one or moreof that entity. As such, the terms “a” (or “an”), “one or more” and “atleast one” can be used interchangeably herein. It is also to be notedthat the terms “comprising”, “including”, and “having” can be usedinterchangeably.

As used herein, “at least one”, “one or more”, and “and/or” areopen-ended expressions that are both conjunctive and disjunctive inoperation. For example, each of the expressions “at least one of A, Band C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “oneor more of A, B, or C” and “A, B, and/or C” means A alone, B alone, Calone, A and B together, A and C together, B and C together, or A, B andC together. When each one of A, B, and C in the above expressions refersto an element, such as X, Y, and Z, or class of elements, such asX₁-X_(n), Y₁-Y_(m), and Z₁-Z_(o), the phrase is intended to refer to asingle element selected from X, Y, and Z, a combination of elementsselected from the same class (e.g., X₁ and X₂) as well as a combinationof elements selected from two or more classes (e.g., Y₁ and Z_(o)).

The term “means” as used herein shall be given its broadest possibleinterpretation in accordance with 35 U.S.C., Section 112, Paragraph 6.Accordingly, a claim incorporating the term “means” shall cover allstructures, materials, or acts set forth herein, and all of theequivalents thereof. Further, the structures, materials or acts and theequivalents thereof shall include all those described in the summary ofthe disclosure, brief description of the drawings, detailed description,abstract, and claims themselves.

Unless otherwise noted, all component or composition levels are inreference to the active portion of that component or composition and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources of suchcomponents or compositions.

All percentages and ratios are calculated by total composition weight,unless indicated otherwise.

It should be understood that every maximum numerical limitation giventhroughout this disclosure is deemed to include each and every lowernumerical limitation as an alternative, as if such lower numericallimitations were expressly written herein. Every minimum numericallimitation given throughout this disclosure is deemed to include eachand every higher numerical limitation as an alternative, as if suchhigher numerical limitations were expressly written herein. Everynumerical range given throughout this disclosure is deemed to includeeach and every narrower numerical range that falls within such broadernumerical range, as if such narrower numerical ranges were all expresslywritten herein. By way of example, the phrase from about 2 to about 4includes the whole number and/or integer ranges from about 2 to about 3,from about 3 to about 4 and each possible range based on real (e.g.,irrational and/or rational) numbers, such as from about 2.1 to about4.9, from about 2.1 to about 3.4, and so on.

The preceding is a simplified summary of the disclosure to provide anunderstanding of some aspects of the disclosure. This summary is neitheran extensive nor exhaustive overview of the disclosure and its variousaspects, embodiments, and configurations. It is intended neither toidentify key or critical elements of the disclosure nor to delineate thescope of the disclosure but to present selected concepts of thedisclosure in a simplified form as an introduction to the more detaileddescription presented below. As will be appreciated, other aspects,embodiments, and configurations of the disclosure are possibleutilizing, alone or in combination, one or more of the features setforth above or described in detail below. Also, while the disclosure ispresented in terms of exemplary embodiments, it should be appreciatedthat individual aspects of the disclosure can be separately claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated into and form a part of thespecification to illustrate several examples of the present disclosure.These drawings, together with the description, explain the principles ofthe disclosure. The drawings simply illustrate preferred and alternativeexamples of how the disclosure can be made and used and are not to beconstrued as limiting the disclosure to only the illustrated anddescribed examples. Further features and advantages will become apparentfrom the following, more detailed, description of the various aspects,embodiments, and configurations of the disclosure, as illustrated by thedrawings referenced below.

FIG. 1 depicts a device according to some embodiments of the presentdisclosure;

FIG. 2 depicts an exploded view of the component having reference number101 in FIG. 1;

FIG. 3 depicts a cross-sectional view of the component having referencenumber 108 in FIG. 1:

FIG. 4 depicts a cross-sectional view of the component having referencenumber 104 in FIG. 1;

FIG. 5 depicts a cross-sectional view of the component having referencenumber 106 in FIG. 1;

FIG. 6 depicts a cross-sectional view of the component having referencenumber 102 in FIG. 1;

FIG. 7 depicts a cross-sectional view of the component having referencenumber 131 in FIG. 1;

FIG. 8 depicts a process according to some embodiments of the presentdisclosure;

FIG. 9 depicts an exploded view of the component having reference number194 in FIG. 1;

FIG. 10 depicts an exploded view of the component having referencenumber 194 in FIG. 9;

FIGS. 11A-11C depict three perspective views of the component havingreference number 200 in FIG. 10;

FIG. 12 is a diagram of the device according to some embodiments of thedisclosure;

FIG. 13 is a plot of the temperature of lubricant-containing vesselaccording to Example 2;

FIG. 14 is a plot of the pressure of lubricant-containing vesselaccording to Example 2;

FIG. 15 is a plot of the temperature of various device componentscontained with the enclosure according to Example 2;

FIG. 16 is a plot of the applicator pressure according to Example 2;

FIG. 17 is plot of the applicator pressure according to Example 3;

FIG. 18 is a plot of the temperature of lubricant-containing vesselaccording to Example 3;

FIG. 19 is a plot of the of the pressure of lubricant-containing vesselaccording to Example 3;

FIG. 20 is a plot of the of the temperature of lubricant-containingvessel according to Example 4;

FIG. 21 is a plot of the of the pressure of lubricant-containing vesselaccording to Example 4;

FIG. 22 is a plot of the temperature of various device componentscontained with the enclosure according to Example 4;

FIG. 23 is a plot of the of the temperature of lubricant-containingvessel according to Example 5;

FIG. 24 is a plot of the of the pressure of lubricant-containing vesselaccording to Example 5;

FIG. 25 is a plot of the of the pressure of applicators according toExample 5;

FIG. 26 is a plot of the temperature of various device componentscontained with the enclosure according to Example 5;

FIG. 27 is a plot of the of the temperature of lubricant-containingvessel according to Example 6;

FIG. 28 is a plot of the of the pressure of lubricant-containing vesselaccording to Example 6;

FIG. 29 is a plot of the temperature of various applicators containedwith the enclosure according to Example 6;

FIG. 30 is a plot of the applicator set temperature according to Example6;

FIG. 31 is a plot of the top prelubrication weights according to Example6;

FIG. 32 is a plot of the bottom prelubrication weights according toExample 6;

FIG. 33 is a plot of the prelubrication viscosity according to Example6;

FIG. 34 is a plot of the of the temperature of lubricant-containingvessel according to Example 7;

FIG. 35 is a plot of the of the pressure of lubricant-containing vesselaccording to Example 7;

FIG. 36 is a plot of the temperature of various applicators containedwith the enclosure according to Example 7;

FIG. 37 is a plot of the applicator set pressure according to Example 7;

FIG. 38 is a plot of the top prelubrication weights according to Example7;

FIG. 39 is a plot of the bottom prelubrication weights according toExample 7; and

FIG. 40 is a plot of the prelubrication viscosity according to Example7.

DETAILED DESCRIPTION

The method discussed herein can apply to stock sheet, with aluminumalloy sheet being illustrative.

FIG. 1 depicts a device 100 according to some embodiments. The device100 can have one or more pairs of applicators 101 a and 101 b, 101 r and101 s, and so forth to 101 y and 101 z with each applicator 101 of themore of more pairs of applicators 101 a and 101 b, 101 r and 101 s, and101 y and 101 z. Each applicator 101 can include a porous applicatorelement 104, a perforated applicator element 108, and aliquid-dispensing element 118 (FIG. 2).

Each applicator 101 of the one or more pair of applicators 101 a and 101b, 101 r and 101 s, and so forth to 101 y and 101 z can have anapplicator axis 126. The liquid-dispensing element 118 is generallypositioned along the applicator axis 126.

The perforated applicator element 108 can have first 122 and second 123perforated element surfaces (FIG. 3). The porous applicator element 104can have first 124 and second 125 porous element surfaces (FIG. 4). Thefirst porous element surface 124 is generally the outer surface of eachapplicator 101 of the one or more applicators 101 a and 101 b, 101 r and101 s, and 101 y and 101 z. Moreover, the second perforated elementsurface 123 is typically the inner surface of each of applicator 101 ofthe one the one or more pair applicators 101 a and 101 b, 101 r and 101s, and 101 y and 101 z. The first perforated element surface 122 isusually in contact with the second porous element surface 125.

The one or more pairs of applicators 101 a and 101 b, 101 r and 101 s,and 101 y and 101 z can be configured consecutively. In someembodiments, the one or more pairs of applicators 101 a and 101 b, 101 rand 101 s, and 101 y and 101 z can include from about two to about threepairs of applicators 101. Moreover, the about two to about six pairs ofapplicators 101 can be configured consecutively. In some embodiments,the one or more pairs of applicators 101 a and 101 b, 101 r and 101 s,and 101 y and 101 z can include three pairs of applicators 101.Furthermore, the three pairs of applicators 101 can be configuredconsecutively.

The perforated applicator element 108 can be one of a metallic material,a polymeric material, or a combination thereof. Generally, theperforated applicator element 108 can be one of steel, stainless steel,aluminum, stainless steel, or brass. More generally, the perforatedapplicator element 108 can be a metallic material. Furthermore, theperforated applicator element 108 can have a plurality of apertures,channels, or a combination thereof substantially uniformly distributedabout most, if not all, of the perforated applicator element 108.Moreover, the perforated applicator element 108 can have a plurality ofapertures, a plurality of channels, or a combination thereofsubstantially uniformly distributed over the perforated applicatorelement surface area. Furthermore, the plurality of apertures, theplurality of channels, or the combination thereof are sufficiently sizedsuch that lubricant is uniformly distributed to the porous applicatorelement 104 and is not retrained by perforated applicator element 108.

The porous applicator element 104 can comprise one of a textilematerial, an organic polymeric material, an inorganic polymericmaterial, or a combination thereof. Furthermore, the porous applicatorelement 104 can comprise one of a felt, a non-woven material, a solidfoam material, a sponge material, or a fabric. Moreover, the porousapplicator element 104 can be permeable, porous, or both porous andpermeable. Usually, the porous applicator element 104 can have a wallthickness from about ⅛ to about ¼ of an inch.

Each pair of applicators 101 can have first 126 a and second 126 bapplicator axes aligned in parallel. First 128 and second outer 129surfaces of the applicators forming each pair of applicators (such as101 a and 101 b, 101 r and 101 s, and 101 y and 101 z) are generallyseparated by a distance sufficient for accepting the stock sheet. Thepressure-adjusting element 107 increases and/or decreases the distancesuch that the first 128 and second 129 outer surfaces of applicators 101can apply a pressure on the stock sheet 102 positioned between the firstand second applicators. It can be appreciated that in some embodiments,the pressure-adjusting element comprises one of an electromechanicaldevice, a solenoid, a pneumatic device, or a combination thereof.Furthermore, the pressure-adjusting element 107 can be one of containedwithin the enclosure 121, external to the enclosure, or partiallycontained within the enclosure 121 and partially contained external tothe enclosure 121.

The liquid-dispensing element 118 generally dispenses a liquidlubricant. The dispensed liquid lubricant generally contacts the secondperforated element surface 123.

The device 100 can also have one or more pressure-adjusting elements107. Typically, each of the applicators 101 has at least onepressure-adjusting element 107.

The device 100 can also have one or more heating elements 105. The oneor more heating elements 105 can be positioned between the enclosure 121and the one or more pairs of applicators 101 a and 101 b, 101 r and 101s, and 101 y and 101 z. The device 100 can include the one or moreheating elements 105 being positioned symmetrically about the one ormore pairs of applicators 101 a and 101 b, 101 r and 101 s, and 101 yand 101 z. Moreover, the one or more heating elements 105 can providesufficient thermal energy to the one or more pairs of applicators 101 aand 101 b, 101 r and 101 s, and 101 y and 101 z to maintain atemperature within the enclosure 121 of from about 80 to 212 degreesFahrenheit, more commonly, more commonly from about 100 to 200 degreesFahrenheit, and even more commonly from about 140 to 195 degreesFahrenheit. Generally, the one or more heating elements 105 can be oneof an electrical resistance heating element, a hot water radiant heatingelement, a stream radiant heating element, a high-pressure steam radiantheating element, a super-critical steam radiant heating element, aninfrared heating element, or a hot oil radiant heating element.

The device 100 can also have an enclosure 121. The enclosure 121 canhave a sheet stock inlet 111 and a sheet stock outlet 113. Moreover, thesheet stock inlet 111 and outlet 113 can be configured for a stock sheet102 to traverse the enclosure 121. The stock sheet 102 can traversemidway between each pair of the one or more pairs of applicators 101 aand 101 b, 101 r and 101 s, and 101 y and 101 z. Typically, theenclosure 121 can be one of an insulated enclosure, a non-insulatedenclosure, or a combination of insulated and non-insulated portions. Theone or more pairs of applicators 101 a and 101 b, 101 r and 101 s, andso forth to 101 y and 101 z and the one or more heating elements 105 canbe contained with the enclosure 121.

The device 100 can also have a lubricant-containing vessel 103. Thelubricant-containing vessel 103 is generally in fluid communication witheach of the liquid-dispensing elements 118 of the applicators 101. Thelubricant-containing vessel 103 is typically in fluid communication witheach of the liquid-dispensing elements 118 through conduit 115.

The device 100 can further include one or more temperature sensingelements 109. The enclosure 109 can have a void volume 130 having a voidvolume temperature. The one or more temperature sensing elements 109 candetermine the void volume temperature. In some embodiments, the one ormore temperature sensing elements 109 can be contained within theenclosure 121. In some embodiments, the one or more temperature sensingelements 109 can be configured external to the enclosure 121. In someembodiments, some of the one or more temperature sensing elements 109can be configured external to the enclosure 121 and the others of theone or more temperature sensing elements 109 can be contained within theenclosure 121.

The lubricant is typically a solid at ambient temperature. Generally,the lubricant-containing vessel 103 can be a heated to maintain thelubricant within the lubricant-containing vessel at a temperaturegreater than the ambient temperature. Commonly, the lubricant-containingvessel 103 contains lubricant in a liquefied form. Thelubricant-containing vessel 103 is generally heated to a temperaturegreater than the ambient temperature to liquefy the lubricant.

The device 100 can further have a pressurizing element (not depicted).The pressurizing element can convey the liquefied lubricant from thelubricant-containing vessel 103 to the liquid-dispensing elements 118 ofeach of the applicators 101.

The device 100 can produce a coil wound sheet 106 (FIG. 5) havingopposing first 110 a and second 110 b sheet surfaces joined together byopposing side edges 117 a and 117 b and opposing ends 119 a and 119 b(FIGS. 6 and 7). The first 110 a and second 110 b sheet surfaces aretypically substantially smooth and planar. The lubricant 114 on the coilwound sheet 106 is generally in the solid form at ambient temperature.That is, the lubricant 114 on the coil wound sheet 106 is typically asolid lubricant. The solid lubricant is generally deposited on the first110 a and second 110 b sheet surfaces. The opposing sheet side edges 117a and 117 b are commonly substantially free of the solid lubricant 114.The lubricated stock sheet 131 generally has from about 3.7 to about13.9 mg per square meter of a lubricant 114 deposited on the sheet 120.

The first 110 a and second 110 b sheet surfaces, respectively, can havefirst and second sheet surface areas. Typically, more than about 95% ofthe first and second sheet surface areas are in contact with the solidlubricant 114. More typically, more than about 98% of the first andsecond sheet surface areas are in contact with the solid lubricant 114.Even more typically, more than about 99% of the first and second sheetsurface areas are in contact with the solid lubricant 114. Yet even moretypically, more than about 99.8% of the first and second sheet surfaceareas are in contact with the solid lubricant 114.

The solid lubricant 114 is generally deposited on the first 110 a andsecond 110 b sheet surfaces of the coil wound sheet 106. The lubricatedstock sheet 131 commonly has a sum total of solid lubricant 114deposited on first 110 a and second 110 b surfaces of the coil woundsheet 106 is from about 3.7 to about 13.9 mg per square meter, morecommonly from about 5.6 to about 11.6 mg per square meter, and even morecommonly from 4.6 to about 9.3 mg per square meter.

The lubricant 114 can have a melting temperature from about 80 to 212degrees Fahrenheit, more commonly, more commonly from about 100 to 200degrees Fahrenheit, and even more commonly from about 140 to 195 degreesFahrenheit.

The lubricant 114 can be a food grade lubricant. The lubricant 114 cancommonly be one or more of a NSF, Kosher or Halal approved food gradelubricant. Generally, the lubricant can be one of dioctylsulfosuccinate, 1-butyl-3-methylimidazoliumbis(trifluoromethylsulfonyl)imide, dioctyl sebacate, bis(2-ethylhexyl)sebacate, sebacic acid di(2-ethylhexyl) ester, hydrotreated heavynaphthenic petroleum distillates, alkenes having a carbon chain lengthgreater than ten, and poly-α-olefin, petrolatum, and mixtures thereof.The lubricate 114 is usually a FDA approved lubricant per 21 CFR178.3910 Paragraph (b). Moreover, the lubricant 114 can qualify as a lowvolatile organic compound under one or more of municipal, state andfederal governing authorities.

The first 110 a and second 110 b sheet surfaces can have can commonlyhave from about 3 mg/foot²/side to about 200 mg/foot²/side of thelubricant, more commonly about 5 mg/foot²/side to about 110mg/foot²/side of the lubricant or even more commonly about 60mg/foot²/side to about 90 mg/foot²/side of the lubricant. In someembodiments, each of the upper and lower surfaces of the sheet cangenerally have about 150±10 mg/foot² of lubricant, more generally about100±10 mg/foot² of lubricant, even more generally about 80±10 mg/foot²of lubricant, and even more generally about 90±10 mg/foot² of lubricant.

The lubricated stock sheet 131 and/or coil wound sheet 106 can be one ofsteel, stainless steel, copper, tin, nickel, gold, platinum, rhodium,aluminum, an organic polymeric material, a metal, an alloyed metal, or acombination thereof. In some embodiments, the lubricated stock sheet 131and/or coil wound sheet 106 can be selected from the group consistingessentially of steel, stainless steel, copper, tin, nickel, gold,platinum, rhodium, aluminum, an organic polymeric material, a metal, analloyed metal, or a combination thereof.

The lubricated stock sheet 131 and/or coil wound sheet 106 can be anautomotive sheet stock.

The lubricated stock sheet 131 and/or coil wound sheet 106 can be a cansheet body, tab or end stock. The can sheet stock can be one an AA 5182series-based alloy, an AA5182ES, AA5182SP, AA5182FE, AA5182M8, an AA3004 series-based alloy, AA3004, AA8011, AA3104, AA35182, AA3104,AA5052, and AA5006. In some embodiments, the can sheet stock can be oneof steel and stainless steel.

In accordance with some embodiments is a process 140 (FIG. 8).

In step 142, a stock sheet 102 is provided. The stock sheet can haveopposing first 110 a and second 110 b stock sheet surfaces joinedtogether by opposing stock sheet side edges 117 a and 117 b and opposingstock sheet ends 119 a and 119 b.

In step 144, the first 110 a and second 110 b stock sheet 102 surfacesare contacted with one or more pairs of applicators 101 a and 101 b, 101r and 101 s, and so forth to 101 y and 101 z to form a lubricated stocksheet 131. Contacting step 144 can include a step of depositing, step147, with each pair of applicators 110 depositing a liquefied lubricant114 on the first 110 a and second 110 b stock sheet surfaces to form thelubricated stock sheet 131.

The first 110 a and second 110 b sheet surfaces are typicallysubstantially smooth and planar. The lubricant 114 on the coil woundsheet 106 is generally in the solid form at ambient temperature. Thatis, the lubricant 114 on the coil wound sheet 106 is typically a solidlubricant. The solid lubricant is generally deposited on the first 110 aand second 110 b sheet surfaces. The opposing sheet side edges 117 a and117 b are commonly substantially free of the solid lubricant 114. Thelubricated stock sheet 131 generally has from about 3.7 to about 13.9 mgper square meter of a lubricant 114 deposited on the sheet 120.

The first 110 a and second 110 b sheet surfaces, respectively, can havefirst and second sheet surface areas. Typically, more than about 95%,more typically, more than about 98%, more typically, more than about99%, and even more typically, more than about 99.8% of the first andsecond sheet surface areas are in contact with the solid lubricant 114.

It can be appreciated that the liquefied lubricant is generally appliedat a temperature greater than the ambient temperature. Moreover, thelubricant is commonly a solid lubricant at ambient temperature, and isusually deposited (on the stock sheet) in a liquefied state. Typically,the contacting step 144 occurs at a temperature from about 80 to 212degrees Fahrenheit, more commonly, more commonly from about 100 to 200degrees Fahrenheit, and even more commonly from about 140 to 195 degreesFahrenheit. Commonly, the opposing stock sheet edges are substantiallyfree of the liquefied lubricant.

Some embodiments can include a step of supplying thermal energy, step141, to the one or more pairs of applicators 101. Generally, the thermalenergy can be supplied by one or more thermal heating elements 105. Theone or more heating elements 105 and the one or more pairs ofapplicators 101 a and 101 b, 101 r and 101 s, and so forth to 101 y and101 z can be contained with an enclosure 121. The one or more thermalheating elements 105 can supply sufficient thermal energy to maintainthe one or pairs of applicators 101 at a temperature from about 80 to212 degrees Fahrenheit, more commonly, more commonly from about 100 to200 degrees Fahrenheit, and even more commonly from about 140 to 195degrees Fahrenheit. The heating elements 105 can be one of an electricalresistance heating element, a hot water radiant heating element, astream radiant heating element, a high-pressure steam radiant heatingelement, a super-critical steam radiant heating element, an infraredheating element, or a hot oil radiant heating element. The enclosure 121can be one of an insulated enclosure, a non-insulated enclosure, or acombination of insulated and non-insulated portions.

In step 146, the lubricated stock sheet 131 is coil wound to form a rollof the lubricated stock sheet 106.

Some embodiments can include a step of flowing, step 143, the liquefiedlubricant 114 from a lubricant-containing vessel 103 to aliquid-dispensing element 118. The step 143 can also include dispensing,from the liquid-dispending element 118, the liquefied lubricant 114 to aperforated applicator element 108 having first 122 and second 123perforated element surfaces. Moreover, the perforated applicator element108 can typically be in fluid communication with the porous applicatorelement 104 having first 124 and second 125 porous element surfaces.Furthermore, the liquefied lubricant can generally flow from the firstperforated element surface 122 to the second porous element surface 125and from the second porous element surface 125 to the first porouselement surface 124.

In some embodiments, the stock sheet can commonly be contacted with eachpair of the one or more pairs of applicators at a rate of about 50 toabout 6,000 feet per minute, more commonly at a rate of about 100 toabout 2,000 feet per minute, or even more commonly at a rate of about400 to about 700 feet per minute.

FIG. 9 depicts in accordance with some embodiments, a sheet lubricantapplication system 190 in operating position to engage stock sheet 102between an oiler 191 and a breakdown roll system 192. The oiler 191 canbe without limitation a Peabody oiler. The breakdown roll system 192generally includes a breakdown roller 193.

As can be seen from FIGS. 9, 10 and 11A-11C, the system 190 includes adrawer assembly 194. The drawer assembly 194 is generally positionedwithin a system mounting 195 by first and second roll caster assemblies196 a and 196 b. The drawer assembly 194 can be removed from the systemmounting 195 by means of the first and second roll cast assemblies 196 aand 196 b.

With reference to FIG. 10, the sheet lubricant application system 190includes an application subassembly 200, valve stack 204, left and rightlubricator supports 208 a and 208 b, bulk head plate 212, heat boxbottom 216 of the drawer assembly 194, heat box top 220 of the drawerassembly 194, heat exchanger fan subassemblies 224 a, 224 b, 224 c, and224 d, hex bolt flanges 228, and fasteners 232 and washers 236. The heatexchanger fan subassemblies 224 a, 224 b, 224 c, and 224 d with eachcomprising a fan and heat exchanger tubing (not depicted), whereby airblown by the fans is heated by hot water in the tubing to heat theapplication subassembly 200 and avoid solidification of the lubricantduring application to the sheet. The valve stack comprises fluid flowmeters to meter lubricant fluid flow to the application rollers.

With reference to FIGS. 3 and 11A-C, the applicator subassembly 200includes six roller subassemblies 304 a-f, a male tee push fitting 308,a pressure regulator assembly 312, an upper roller carrier 316, a pivotreplacement pin 320, a pivot bracket 324, an air cylinder assembly 330,a push-in swivel elbow 334, lower roller carrier 338, a dispenserassembly 342, a mounting bracket for the air cylinder 346, a stub shaftwith a jam nut 350, a tube guard 354, a T-slot extrusion 358, and adouble endplate with cut outs 362. The adjacent roller subassemblies 304move up and down to adjustably engage the sheet. The pressure regulatorassembly 312 measures the pressure applied by each adjacent pair ofroller subassemblies to the sheet.

With reference to FIG. 4, each roller subassembly 204 comprises aliquid-dispensing element 118, porous applicator element 104, perforatedapplicator element 108, roller end caps (which includes the bearing) 112a,b, bearing 116, and stub shaft 120. As can be seen from the assembledcutaway, the liquid-dispensing element 118 passes through the end cap1112 a and 112 b and includes orifices 132 along its length to dispenseheated liquid lubricant. 114 in liquefied form. The liquid lubricant 114flows through the perforations in the perforated applicator element 108to soak the porous applicator element 104, which contacts the stocksheet 102 and applies liquid lubricant 114 to the stock sheet 102 byroll coating techniques under controlled pressure, allowing precisecontrol of the amount of lubricant 114 applied. The opposing pairs ofroller subassemblies apply lubricant to opposing surfaces of the stocksheet 102. The porous applicator element 104 is commonly one or more ofpolyurethane foam, polyester felt, or wool felt.

With reference to FIG. 12, the control circuitry and ancillary equipmentfor the lubricant application system 190 is depicted. The lubricantapplication system 190 comprises first and second lubricant heatingvessels 400 a,b, which heat and melt the solid lubricant by means ofheating assemblies 404. The heated lubricant is mixed by impellers 408.The heated lubricant is transported to the lube dispensing vessel 416,which is also heated by a heating assembly 404. Under the pressure ofair, the heated liquid lubricant passes pneumatically along heated lubeprocess piping 412 to the lubricant injectors 300 for introduction intothe roller subassemblies 204.

The control circuitry includes the following components: electricalsupply (ES), flow controller (FC), timer alarm high (KAH), pressureindicator (PI), (to indicate pressure in the pneumatic signal lines),pressure alarm high (PAH), pressure alarm low (PAL), pressuretransmitter (PT), (to transmit pressure measurements in the pneumaticsignal lines), solenoid valve (SOV), temperature element (TE), (inmeasure temperatures in each of the lube dispensing vessel 416, lubedrum preheat station 400 a and lube drum dispensing station 400 b, thetransfer piping, and the enclosure), temperature indicator (TI), (totransmit temperature measurements), temperature indicating controller(TIC), temperature controller (TC), (controlling the temperatures in thelube process piping, the lube dispensing vessel 416, lube drum preheatstation 400 a and lube drum dispensing station 400 b), temperature alarmhigh (TAH), and temperature alarm low (TAL). Other component types inthe lubricant application system 190 include lube process piping(connecting the lube dispensing vessel 416 with the lubricant injectors300 to apply pressure), water supply, pneumatic signal (line),(connecting plant air with each of the lubricant injectors 300 and thelube dispensing vessel 416), electrical signal (line), ethernetconnection, manual valve, solenoid valve, self-relieving pressureregulator (with manually adjustable set point) (to regulate pressure inthe pneumatic signal lines), motor, heating element (to provide thermalenergy in response to input from the temperature controller), manualpressure relief valve, fan (to heat the enclosure), filter, and visualalarm (showing alarm type designator and alarm set point value).

Control subassemblies include for the first and second lubricant heatingvessels 400 a,b, and lube dispensing vessel 416 include a temperaturecontroller and temperature element pairing to monitor the temperature ofthe lubricant.

Control subassembly for the heated lube process piping 412 temperaturecontroller and temperature element to monitor piping temperature (andavoid lubricant solidification in the piping during pneumatic transport.

Control subassemblies for each of the roller subassemblies 204 include aproximity sensor (to detect roller subassembly speed or rotation rate toshut down automatically the device in the event of a rate above or belowset thresholds) and solenoid valves to shut down the flow of liquidlubricant in the event of system malfunction or shut down. A temperatureelement and control can be engaged with the lubricant supply to orwithin each roller subassembly 204 to shut down automatically the devicein the event a measured temperature between a first and second rollersubassemblies exceeds a set threshold.

The drawer assembly 194 is engaged with a proximity sensor to determinewhen the drawer assembly 194 is not in a proper (operative) position.When the proximity sensor detects that the drawer assembly 194 is in animproper position, the system is rendered inoperative.

The lubricant typically has a melt point typically no more than about250% above, more typically no more than about 200% above, more typicallyno more than about 150% above, and even more typically no more thanabout 100% above ambient temperature. In one application, the lubricanthas a melt point at or slightly above (typically no more than about 35%above and more typically no more than about 25% above) ambienttemperature. In one application, the melt point of the lubricant rangesfrom ambient temperature (or slightly above room temperature) commonlyfrom about 80 to 212 degrees Fahrenheit, more commonly, more commonlyfrom about 100 to 200 degrees Fahrenheit, and even more commonly fromabout 140 to 195 degrees Fahrenheit. Ambient temperature typicallyranges from about 12 to about 3 and more typically from about 18 toabout 27 degrees Celsius. The lubricant can be any oil, soluble oil,semisynthetic, and dry-film. In addition to having good lubricity,lubricants should be easily removable from the formed sheet, because thecan body has to be completely oil-free for painting. Therefore, inselection/evaluation of stamping lubricants, one should consideradvantages and disadvantages of lubricants not only for deep drawing butalso for assembly and painting operations. Examples of suitablelubricants include AMCO5157™, Quakerol Pre Lube™, AMCO5357™, andO4C-172™.

In one configuration, the sheet lubricant application system 190 can beset to apply, to each of the upper and lower surfaces of the sheet,about 150±10 mg/foot² of lubricant, more commonly about 100±10 mg/foot²of lubricant, even more commonly about 80±10 mg/foot² of lubricant, andeven more commonly about 90±10 mg/foot² of lubricant.

EXPERIMENTAL

The following examples are provided to illustrate certain aspects,embodiments, and configurations of the disclosure and are not to beconstrued as limitations on the disclosure, as set forth in the appendedclaims. All parts and percentages are by weight unless otherwisespecified.

Three different lubricants (I, II, and III) where applied to a standardaluminum can stock sheet according to the above methods and sample atten different locations on the coil wound coil. Table 1 shows that thelubricant was substantially uniformly distributed on the stock sheet.

TABLE 1 Cut (lubricant weights mg/ft²) Lubricant 1 2 3 4 5 6 7 8 9 10 I63 60 65 58 55 60 61 67 69 65 II 67 61 59 62 49 47 55 66 70 64 IIIA 5858 52 47 48 44 60 53 55 57 IIIB 59 68 66 70 61 60 60 65 56 62

Example 2

Lubricant was applied to a standard aluminum can stock sheet accordingto the process parameters of Table 2. FIGS. 13-16 show that thelubricant-containing vessel temperature and pressure and the applicatortemperature and pressure can be substantially controlled in theabove-identified process.

Example 3

Lubricant was applied to a standard aluminum can stock sheet accordingto the process parameters of Table 3. FIGS. 17-19 show that thelubricant-containing vessel temperature and pressure and the applicatorpressure can be substantially controlled in the above-identifiedprocess.

Example 4

Lubricant was applied to a standard aluminum can stock sheet accordingto the process parameters of Table 4. FIGS. 20-22 show that thelubricant-containing vessel temperature and pressure and the temperaturewithin the enclosure can be substantially controlled in theabove-identified process.

Example 5

Lubricant was applied to a standard aluminum can stock sheet accordingto the process parameters of Table 5. FIGS. 23-26 show that thelubricant-containing vessel temperature and pressure and the applicatortemperature at various locations and pressure can be substantiallycontrolled in the above-identified process.

Example 6

Lubricant was applied to a standard aluminum can stock sheet accordingto the Lubricant was applied to a standard aluminum can stock sheetaccording to the process parameters of Table 6. FIGS. 27-35 show thatthe lubricant-containing vessel temperature and pressure, the applicatortemperature at various locations and pressure, lubricant viscosity, andamount of lubricant deposited on opposing sides of the stock sheet canall be substantially controlled in the above-identified process.

Example 7

Lubricant was applied to a standard aluminum can stock sheet accordingto the Lubricant was applied to a standard aluminum can stock sheetaccording to the process parameters of Table 7. FIGS. 34-40 show thatthe lubricant-containing vessel temperature and pressure, the applicatortemperature at various locations and pressure, lubricant viscosity, andamount of lubricant deposited on opposing sides of the stock sheet canall be substantially controlled in the above-identified process.

A number of variations and modifications of the disclosure can be used.It would be possible to provide for some features of the disclosurewithout providing others.

TABLE 2 Fractional Distance from Start to End of Process Spiral WoundRoll Conditions start ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ end Lube Pot ° F. 146 145 144 144143 142 141 140 146 Lube Pot PSI 50 50 50 50 50 50 50 50 50 RollerAssembly 194 192 193 193 193 192 193 192 194 OP ° F. Roller Assembly 180179 179 179 179 179 179 180 180 Center ° F. Roller Assembly 187 186 187185 186 186 185 186 187 Drive ° F. Roll Set PSI 30 30 30 30 30 30 30 3030

TABLE 3 Fractional Distance from Start to End of Spiral Wound RollProcess Conditions start ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ end Lube Pot ° F. 141 141 140 142142 142 142 141 141 Lube Pot PSI 50 50 50 50 50 50 50 50 50 RollerAssembly OP ° F. 192 191 191 191 191 191 191 191 192 Roller AssemblyCenter ° F. 178 178 177 178 178 178 178 178 178 Roller Assembly Drive °F. 192 192 191 192 191 191 191 191 192 Roll Set PSI 30 30 30 30 30 30 3030 30

TABLE 4 Fractional Distance from Start to End of Spiral Wound RollProcess Conditions start ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ end Lube Pot ° F. 141 143 143 141140 141 142 142 141 Lube Pot PSI 50 50 50 50 50 50 50 50 50 RollerAssembly OP ° F. 191 191 191 191 191 191 191 191 191 Roller AssemblyCenter ° F. 176 175 175 175 175 175 175 174 175 Roller Assembly Drive °F. 191 191 191 191 191 191 191 191 191 Roll Set PSI 30 30 30 30 30 30 3030 30

TABLE 5 Fractional Distance from Start to End of Spiral Wound RollProcess Conditions start ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ end Lube Pot ° F. 144 140 140 143142 140 142 141 144 Lube Pot PSI 50 50 50 50 50 50 50 50 50 RollerAssembly OP ° F. 191 190 190 190 190 190 190 190 191 Roller AssemblyCenter ° F. 178 176 175 175 176 175 176 177 178 Roller Assembly Drive °F. 189 188 188 189 189 189 188 189 189 Roll Set PSI 30 30 30 30 30 30 3030 30

TABLE 6 Fractional Distance from Start to End of Spiral Wound RollProcess Conditions start ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ end Lube Pot ° F. 141 141 143 141141 143 142 144 141 Lube Pot PSI 50 50.5 50 50 50.5 50 50 50 50 RollerAssembly 195 194 195 193 194 194.5 194 194 195 OP ° F. Roller Assembly181 181 179 178 179 180 179 180 180 Center ° F. Roller Assembly 195194.5 195 195 194.5 195 195 195 194 Drive ° F. Roll Set PSI 30 30 30 3030 30 30 30 30

TABLE 7 Fractional Distance from Start to End of Spiral Wound RollProcess Conditions start ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ end Lube Pot ° F. 139 140 142 141141 142 142 142 143 Lube Pot PSI 50 50.0 50 50 50.0 50 50 50 50 RollerAssembly 197 196 195 195 195 195 196 195 195 OP ° F. Roller Assembly 180178 178 176 176 177 177 177 177 Center ° F. Roller Assembly 195 194 194194 195 195 195 194 195 Drive ° F. Roll Set PSI 30 30 30 30 30 30 30 3030

A number of variations and modifications of the disclosure can be used.It would be possible to provide for some features of the disclosurewithout providing others.

In accordance with some embodiments, the step of providing the stocksheet can be providing an automotive sheet stock.

In accordance with some embodiments, the step of providing the stocksheet can be providing a can body, end or tab sheet stock. Moreover, thecan sheet stock is one of an AA 5182 series-based alloy, an AA5182ES,AA5182SP, AA5182FE, AA5182M8, an AA 3004 series-based alloy, AA3004,AA8011, AA3104, AA35182, AA3104, AA5052, and AA5006. Furthermore, thecan sheet stock is one of steel and stainless steel.

An AA 5182 series-based alloy (e.g., AA 5182ES and SP) is useful forproducing end stock. The AA 5182 series-based alloy generally has thefollowing composition:

(i) from about 0.20 to about 0.50%, even more commonly from about 0.225to about 0.45%, and even more commonly from about 0.250 to about 0.35%by weight manganese;

(ii) from about 4.0 to about 4.95%, even more commonly from about 4.5 toabout 5%, and even more commonly from about 4.7 to about 4.95% by weightmagnesium;

(iii) from about 0.001 to about 0.15%, even more commonly from about0.005 to about 0.11%, and even more commonly from about 0.01 to about0.08% by weight copper;

(iv) from about 0.01 to about 0.35%, even more commonly from about 0.015to about 0.30%, and even more commonly from about 0.020 to about 0.25%by weight iron; and

(v) from about 0.01 to about 0.20%, even more commonly from about 0.015to about 0.175%, and even more commonly from about 0.05 to about 0.15%by weight silicon;

(vi) from about 0.01 to about 0.25%, even more commonly from about 0.025to about 0.15%, and even more commonly from about 0.05 to about 0.1% byweight chromium;

(vii) from about 0.01 to about 0.25%, even more commonly from about0.051 to about 0.20%, and even more commonly from about 0.075 to about0.175% by weight zinc;

(vii) from about 0.001 to about 0.01% and even more commonly from about0.001 to about 0.075% by weight nickel; and

(viii) from about 0.001 to about 0.1%, even more commonly from about0.005 to about 0.075%, and even more commonly from about 0.01 to about0.07% by weight titanium.

An AA 5182 series-based alloy (e.g., AA 5182SP and FE) can be useful forproducing tab stock. The AA 5182 series-based alloy typically has thefollowing composition:

(i) from about 0.20 to about 0.50%, even more commonly from about 0.225to about 0.45%, and even more commonly from about 0.250 to about 0.35%by weight manganese;

(ii) from about 4.0 to about 5%, even more commonly from about 4.2 toabout 4.8%, and even more commonly from about 4.3 to about 4.6% byweight magnesium or in an alternative formulation even more commonlyfrom about 4.8 to about 4.95% by weight magnesium;

(iii) from about 0.001 to about 0.1%, even more commonly from about0.005 to about 0.09%, and even more commonly from about 0.01 to about0.08% by weight copper;

(iv) from about 0.01 to about 0.35%, even more commonly from about 0.015to about 0.30%, and even more commonly from about 0.020 to about 0.29%by weight iron; and

(v) from about 0.01 to about 0.20%, even more commonly from about 0.015to about 0.175%, and even more commonly from about 0.05 to about 0.15%by weight silicon;

(vi) from about 0.01 to about 0.25%, even more commonly from about 0.025to about 0.15%, and even more commonly from about 0.05 to about 0.1% byweight chromium;

(vii) from about 0.01 to about 0.25%, even more commonly from about0.051 to about 0.20%, and even more commonly from about 0.075 to about0.175% by weight zinc;

(vii) from about 0.001 to about 0.01% and even more commonly from about0.001 to about 0.075% by weight nickel; and

(viii) from about 0.001 to about 0.1%, even more commonly from about0.005 to about 0.075%, and even more commonly from about 0.01 to about0.07% by weight titanium.

An AA 5182M8 series-based alloy useful for producing tab stock. The AA5182M8 series-based alloy generally has the following composition:

(i) from about 0.20 to about 0.50%, even more commonly from about 0.25to about 0.45%, and even more commonly from about 0.275 to about 0.425%by weight manganese;

(ii) from about 4 to about 5%, even more commonly from about 4.1 toabout 4.7%, and even more commonly from about 4.15 to about 4.5% byweight magnesium;

(iii) from about 0.001 to about 0.1%, even more commonly from about 0.01to about 0.09%, and even more commonly from about 0.015 to about 0.08%by weight copper;

(iv) from about 0.01 to about 0.35%, even more commonly from about 0.050to about 0.30%, and even more commonly from about 0.075 to about 0.25%by weight iron; and

(v) from about 0.001 to about 0.20%, even more commonly from about 0.01to about 0.175%, and even more commonly from about 0.05 to about 0.15%by weight silicon;

(vi) from about 0.001 to about 0.1%, even more commonly from about 0.01to about 0.075%, and even more commonly from about 0.025 to about 0.050%by weight chromium;

(vii) from about 0.001 to about 0.01% by weight nickel;

(viii) from about 0.001 to about 0.1%, even more commonly from about0.01 to about 0.09%, and even more commonly from about 0.015 to about0.08% by weight titanium; and

(ix) from about 0.01 to about 0.25%, even more commonly from about 0.015to about 0.20%, and even more commonly from about 0.025 to about 0.15%by weight zinc.

An AA 3004 series-based aluminum alloy (e.g., AA 5182ES and SP) isuseful for producing body stock. The AA 3304 series-based aluminum alloycan have the following composition:

(i) from about 0.75 to about 2.00%, even more commonly from about 0.85to about 1.85%, and even more commonly from about 1 to about 1.5% byweight manganese;

(ii) from about 0.5 to about 1.5%, even more commonly from about 0.65 toabout 1.4%, and even more commonly from about 0.8 to about 1.3% byweight magnesium;

(iii) from about 0.001 to about 0.35%, even more commonly from about0.005 to about 0.30%, and even more commonly from about 0.01 to about0.25% by weight copper;

(iv) from about 0.001 to about 0.9%, even more commonly from about 0.005to about 0.8%, and even more commonly from about 0.001 to about 0.7% byweight iron; and

(v) from about 0.01 to about 0.40%, even more commonly from about 0.015to about 0.35%, and even more commonly from about 0.05 to about 0.3% byweight silicon;

(vi) from about 0.01 to about 0.25%, even more commonly from about 0.025to about 0.15%, and even more commonly from about 0.05 to about 0.1% byweight chromium;

(vii) from about 0.01 to about 0.25%, even more commonly from about0.051 to about 0.20%, and even more commonly from about 0.075 to about0.175% by weight zinc;

(vii) from about 0.001 to about 0.01% and even more commonly from about0.001 to about 0.075% by weight nickel; and

(viii) from about 0.001 to about 0.1%, even more commonly from about0.005 to about 0.075%, and even more commonly from about 0.01 to about0.07% by weight titanium.

It can be appreciated that any of above-identified alloy alloys cancontain other elements. Typically, the elements other than thoseindicated in the above-identified aluminum alloys (AA 5182, AA51892M8,and AA3004 series-based) constitute no more than about 0.15% by weightof the composition.

In some embodiments, the metal sheet is aluminum sheet having AA 5182specifications and that is used for end or tab stock manufacture. AA3004 commonly includes 0.9 to 1.1 wt. % magnesium and 0.9 to 1 wt. %manganese, while AA 5182 commonly includes from 4.6 to 4.9 wt. %magnesium and from 0.20 to 0.50 wt. % and more commonly no more than0.35 wt. % manganese.

The present disclosure, in various aspects, embodiments, andconfigurations, includes components, methods, processes, systems and/orapparatus substantially as depicted and described herein, includingvarious aspects, embodiments, configurations, subcombinations, andsubsets thereof. Those of skill in the art will understand how to makeand use the various aspects, aspects, embodiments, and configurations,after understanding the present disclosure. The present disclosure, invarious aspects, embodiments, and configurations, includes providingdevices and processes in the absence of items not depicted and/ordescribed herein or in various aspects, embodiments, and configurationshereof, including in the absence of such items as may have been used inprevious devices or processes, e.g., for improving performance,achieving ease and\or reducing cost of implementation.

The foregoing discussion of the disclosure has been presented forpurposes of illustration and description. The foregoing is not intendedto limit the disclosure to the form or forms disclosed herein. In theforegoing Detailed Description for example, various features of thedisclosure are grouped together in one or more, aspects, embodiments,and configurations for the purpose of streamlining the disclosure. Thefeatures of the aspects, embodiments, and configurations of thedisclosure may be combined in alternate aspects, embodiments, andconfigurations other than those discussed above. This method ofdisclosure is not to be interpreted as reflecting an intention that theclaimed disclosure requires more features than are expressly recited ineach claim. Rather, as the following claims reflect, inventive aspectslie in less than all features of a single foregoing disclosed aspects,embodiments, and configurations. Thus, the following claims are herebyincorporated into this Detailed Description, with each claim standing onits own as a separate preferred embodiment of the disclosure.

Moreover, though the description of the disclosure has includeddescription of one or more aspects, embodiments, or configurations andcertain variations and modifications, other variations, combinations,and modifications are within the scope of the disclosure, e.g., as maybe within the skill and knowledge of those in the art, afterunderstanding the present disclosure. It is intended to obtain rightswhich include alternative aspects, embodiments, and configurations tothe extent permitted, including alternate, interchangeable and/orequivalent structures, functions, ranges or steps to those claimed,whether or not such alternate, interchangeable and/or equivalentstructures, functions, ranges or steps are disclosed herein, and withoutintending to publicly dedicate any patentable subject matter.

What is claimed is:
 1. A method, comprising: heating a solid lubricantto form a liquid lubricant; flowing the liquid lubricant to one or morepairs of applicators contained in an enclosure comprising a sheet inletand a sheet outlet, wherein the enclosure is one or more of heated andinsulated and wherein the enclosure is maintained at a temperature offrom about 80 to 212 degrees Fahrenheit; passing a stock sheet havingopposing planar first and second stock sheet surfaces joined together byopposing stock sheet side edges and opposing stock sheet ends throughthe sheet inlet and the sheet outlet; contacting the first and secondstock sheet surfaces with the one or more pairs of applicators to form alubricated stock sheet, wherein each of the one or more pairs ofapplicators deposits the liquid lubricant on the first and second stocksheet surfaces, and wherein no more than a total of from about 3mg/foot²/side to about 200 mg/foot²/side of the liquid lubricant isdeposited on the first and second stock sheet surfaces by the one ormore pairs of applicators; and winding the lubricated stock sheet into acoil.
 2. The method of claim 1, wherein a melting temperature of thesolid lubricant ranges from about 100 to about 200 degrees Fahrenheit,wherein no more than a total of from about 5 mg/foot²/side to about 110mg/foot²/side of the liquid lubricant is deposited on the first andsecond stock sheet surfaces by the one or more pairs of applicators, andwherein the flowing and contacting further comprises: applying airpressure to a headspace of a lubricant-containing vessel to cause theliquid lubricant to flow pneumatically to the one or more pairs ofapplicators; flowing the liquid lubricant from the lubricant-containingvessel to a perforated applicator element having first and secondperforated element surfaces, wherein the perforated applicator elementis in fluid communication with a porous applicator element having firstand second porous element surfaces, wherein the liquid lubricant flowsfrom the first perforated element surface to the second porous elementsurface and from the second porous element surface to the first porouselement surface, and wherein the contacting further comprises contactingthe first porous element surface with the first and second stock sheetsurfaces to deposit the liquid lubricant on the stock sheet.
 3. Themethod of claim 2, wherein the first perforated element surface is inphysical contact with the second porous element surface, wherein themelting temperature of the solid lubricant ranges from about 140 toabout 195 degrees Fahrenheit, wherein the dispensed liquid lubricantforms a substantially continuous and substantially uniform lubricantlayer on each of the first and second stock sheet surfaces of thelubricated stock sheet, wherein the perforated applicator elementcomprises a metallic material, a polymeric material, or a combinationthereof, wherein the perforated applicator element comprises a pluralityof apertures, a plurality of channels, or a combination thereofsubstantially uniformly distributed over the first and second perforatedelement surfaces, wherein the porous applicator element comprises atextile material, an organic polymeric material, an inorganic polymericmaterial, or a combination thereof, wherein the porous applicatorelement is permeable, porous, or both porous and permeable, wherein theenclosure is heated and further comprising: supplying thermal energy tothe one or more pairs of applicators, wherein the thermal energy issupplied by one or more thermal heating elements contained within theenclosure and positioned between the one or more pairs of applicatorsand the enclosure; and controlling, in response to input from a pressureindicator and by a pressure-adjusting element, a pressure applied to thefirst and second stock sheet surfaces by the porous applicator elementto deposit the liquid lubricant on the stock sheet, wherein thepressure-adjusting element comprises one of an electromechanical device,a solenoid, a pneumatic device, or a combination thereof.
 4. The methodof claim 1, wherein a melting temperature of the solid lubricant rangesfrom about 80 to about 212 degrees Fahrenheit, wherein the first andsecond stock sheet surfaces, respectively, have first and second sheetsurface areas, and wherein the contacting further comprises depositingthe liquid lubricant on from about 99 to about 100% of the first andsecond sheet surface areas.
 5. The method of claim 1, wherein thecontacting further comprises contacting the stock sheet with the one ormore pairs of applicators while the stock sheet is moving at a rate ofabout 100 to about 2,000 feet/minute, and wherein each of the first andsecond sheet surfaces comprises from about 60 mg/foot²/side to about 90mg/foot²/side of the liquid lubricant.
 6. The method of claim 1, whereinthe enclosure is heated and further comprising supplying thermal energyto the one or more pairs of applicators, wherein the thermal energy issupplied by plural thermal heating elements positioned within theenclosure, wherein the plural heating elements are positionedsymmetrically about the one or more pairs of applicators, and whereineach of the first and second sheet surfaces has from about 60mg/foot²/side to about 90 mg/foot²/side of the liquid lubricant.
 7. Themethod of claim 1, wherein each of the first and second sheet surfaceshas from about 90 to about 100 mg/foot²/side with a variation inthickness of about ±10 mg/foot²/side of the liquid lubricant.
 8. Themethod of claim 1, wherein one or more temperature sensing elementsdetermine the enclosure temperature and a temperature controllermaintains the enclosure temperature in the range of from about 80 to 212degrees Fahrenheit and further comprising heating the enclosure usinghot air produced from a heat exchanger fan subassembly comprising one ormore fans and one or more heat exchanger elements.
 9. The method ofclaim 1, wherein from about 3.7 to about 13.9 mg/square meter of theliquid lubricant is deposited on the stock sheet by the one or morepairs of applicators, wherein the one or more pairs of applicatorscontact the first and second sheet surfaces at a rate of from about 50to about 6,000 feet/minute, wherein one or more of the following istrue: (i) the solid lubricant is one or more of a NSF, Kosher or Halalapproved food grade lubricant; (ii) the solid lubricant is one ofdioctyl sulfosuccinate, 1-butyl-3-methylimidazoliumbis(trifluoromethylsulfonyl)imide, dioctyl sebacate, bis(2-ethylhexyl)sebacate, sebacic acid di(2-ethylhexyl) ester, hydrotreated heavynaphthenic petroleum distillates, alkenes having a carbon chain lengthgreater than ten, and poly-α-olefin, petrolatum, and mixtures thereof;(iii) the solid lubricate is FDA approved per 21 CFR 178.3910 Paragraph(b); and (iv) the solid lubricant qualifies as a low volatile organiccompound under one or more of municipal, state and federal governingauthorities and wherein the heating comprises monitoring, by atemperature element, a temperature in a lubricant-heating vessel andheating, in response to input from a temperature controller incommunication with the temperature element, the solid lubricant in thelubricant-heating vessel.
 10. The method of claim 1, wherein theenclosure is heated and further comprising: supplying thermal energy tothe one or more pairs of applicators, wherein the thermal energy issupplied by multiple thermal heating elements positioned within theenclosure, wherein the heating elements are positioned symmetricallyabout the one or more pairs of applicators, and wherein the stock sheetcomprises one of steel, stainless steel, copper, tin, nickel, gold,platinum, rhodium, aluminum, an organic polymeric material, a metal, analloyed metal, and a combination thereof.
 11. The method of claim 2,wherein the heating comprises monitoring, by a first temperatureelement, a temperature in a lubricant-containing vessel and heating, inresponse to input from a temperature controller in communication withthe first temperature element, the solid lubricant in thelubricant-containing vessel, wherein the heating comprises monitoring,by a second temperature element, a temperature in process pipingtransporting the liquid lubricant from the lubricant-containing vesselto the one or more pairs of applicators and heating, in response toinput from the temperature controller in communication with the secondtemperature element, the lubricant in the process piping, and wherein,prior to the contacting, first and second side edges of the stock sheetare substantially free of the liquid and/or the solid lubricant.
 12. Themethod of claim 1, wherein the heating comprises monitoring, by a firsttemperature element, a temperature in a lubricant-containing vessel andheating, in response to input from a temperature controller incommunication with the first temperature element, the solid lubricant inthe lubricant-containing vessel, wherein the heating comprisesmonitoring, by a second temperature element, a temperature in processpiping transporting the liquid lubricant from the lubricant-containingvessel to the one or more pairs of applicators and heating, in responseto input from the temperature controller in communication with thesecond temperature element, the lubricant in the process piping, andwherein opposing stock sheet side edges are substantially free of theliquid lubricant.
 13. A method of claim 2, wherein the heatingcomprises: measuring, by a first temperature element, a firsttemperature in one or more lubricant heating vessels; heating, inresponse to commands from a temperature controller, the solid lubricantin the one or more lubricant heating vessels to form the liquidlubricant; transferring the liquid lubricant from the one or morelubricant heating vessels to the lubricant-containing vessel; measuring,by a second temperature element, a second temperature of one or moreheated transfer lines; heating, in response to commands from thetemperature controller, the one or more heated transfer lines; andflowing the liquid lubricant from the lubricant-containing vessel to theone or more pairs of applicators through the one or more heated transferlines.
 14. A method comprising: heating a solid lubricant to form aliquid lubricant; flowing pneumatically the liquid lubricant, under airpressure, from a heated lubricant-containing vessel through one or moreheated transfer lines to one or more pairs of applicators comprising aperforated applicator element having first and second perforated elementsurfaces, wherein the perforated applicator element is in fluidcommunication with a porous applicator element having first and secondporous element surfaces, wherein the liquid lubricant flows from thefirst perforated element surface to the second porous element surfaceand from the second porous element surface to the first porous elementsurface, and wherein the one or more pairs of applicators is containedin an enclosure comprising a sheet inlet to receive a stock sheet and asheet outlet to output a lubricated stock sheet, wherein the enclosureis one or more of heated and insulated; contacting the first porouselement surface with the stock sheet comprising opposing substantiallyplanar first and second surfaces to deposit the liquid lubricant on thefirst and second surfaces and form the lubricated stock sheet, whereinthe contacting occurs at a temperature from about 80 to 212 degreesFahrenheit; and forming the lubricated stock sheet into a coil.
 15. Themethod of claim 14, wherein a melting temperature of the solid lubricantranges from about 100 to about 200 degrees Fahrenheit, wherein no morethan a total of from about 5 mg/foot²/side to about 110 mg/foot²/side ofthe liquid lubricant is deposited on the stock sheet by the one or morepairs of applicators, and further comprising: applying air pressure to aheadspace of the heated lubricant-containing vessel to causepneumatically the liquid lubricant to flow under air pressure to the oneor more pairs of applicators; passing the stock sheet through the sheetinlet of the thermally insulated and heated enclosure and the sheetoutlet configured for the stock sheet to traverse the enclosure andwherein the contacting occurs within the enclosure, wherein one or moretemperature sensing elements determines an enclosure temperature and atemperature controller maintains the enclosure temperature in the rangeof from about 80 to 212 degrees Fahrenheit; and controlling, in responseto input from a pressure indicator, a pressure applied to the first andsecond stock sheet surfaces by the porous applicator element to depositthe liquid lubricant on the stock sheet, wherein the pressure adjustingelement comprises one of an electromechanical device, a solenoid, apneumatic device, or a combination thereof.
 16. The method of claim 15,wherein the enclosure is heated, wherein the first perforated elementsurface is in contact with the second porous element surface, whereinthe melting temperature of the solid lubricant ranges from about 140 toabout 195 degrees Fahrenheit, wherein the dispensed liquid lubricantforms a substantially continuous and substantially uniform lubricantlayer on the lubricated stock sheet, wherein the perforated applicatorelement comprises a metallic material, a polymeric material, or acombination thereof, wherein the perforated applicator element comprisesa plurality of apertures, a plurality of channels, or a combinationthereof substantially uniformly distributed over the first and secondperforated element surfaces, wherein the porous applicator elementcomprises a textile material, an organic polymeric material, aninorganic polymeric material, or a combination thereof, and wherein theporous applicator element is permeable, porous, or both porous andpermeable, and further comprising: supplying thermal energy to the oneor more pairs of applicators, wherein the thermal energy is supplied byone or more heating elements, and wherein the one or more heatingelements are contained within the enclosure in thermal proximity to theone or more pairs of applicators.
 17. The method of claim 14, whereinfrom about 3.7 to about 13.9 mg/square meter of the liquid lubricant isdeposited on the stock sheet by the one or more pairs of applicators,wherein the one or more pairs of applicators contact the first andsecond sheet surfaces at a rate of about 50 to about 6,000 feet/minute,wherein the heating step comprises monitoring, by a temperature element,a temperature in the heated lubricant-containing vessel and heating, inresponse to input from a temperature controller in communication withthe temperature element, the solid lubricant in the heatedlubricant-containing vessel, and wherein the contacting step furthercomprises one or more of the following: (i)depositing liquid lubricanton from about 99 to about 100% of the first and second sheet surfaces ofthe stock sheet; and (ii) depositing no more than a total of from about3 mg/foot²/side to about 200 mg/foot²/side of the liquid lubricant onthe stock sheet by the one or more pairs of applicators.
 18. The methodof claim 14, wherein the heating step comprises monitoring, by a firsttemperature element, a temperature in the heated lubricant-containingvessel and heating, in response to input from a temperature controllerin communication with the first temperature element, the solid lubricantin the heated lubricant-containing vessel, wherein the heating stepcomprises monitoring, by a second temperature element, a temperature inprocess piping transporting the liquid lubricant from the heatedlubricant-containing vessel to the one or more pairs of applicators andheating, in response to input from the temperature controller incommunication with the second temperature element, the process piping,and wherein each of the first and second surfaces of the stock sheet hasfrom about 90 to about 100 mg/foot²/side with a variation in thicknessof about ±10 mg/foot²/side of the liquid lubricant and wherein each ofthe first and second sheet surfaces has from about 60 mg/foot²/side toabout 90 mg/foot²/side of the liquid lubricant.
 19. A method,comprising: providing a stock sheet having opposing substantially planarfirst and second stock sheet surfaces joined together by opposing stocksheet side edges and opposing stock sheet ends; passing the stock sheetthrough an enclosure comprising a sheet inlet and a sheet outletconfigured for the stock sheet to traverse the enclosure and to maintaina liquid lubricant in liquid form, wherein the enclosure is one or moreof heated and insulated; contacting at least one of the first and secondstock sheet surfaces with one or more pairs of applicators locatedwithin the enclosure to form a lubricated stock sheet, wherein each pairof applicators in the one or more pairs of applicators deposits theliquid lubricant to form a substantially continuous and substantiallyuniform lubricant layer on at least one of the first and second stocksheet surfaces, wherein the contacting occurs at a temperature of fromabout 80 to about 212 degrees Fahrenheit, wherein the liquid lubricantis a solid lubricant at ambient temperature, and wherein at least one ofthe following is true: (i)the contacting occurs while the stock sheet ismoving at a rate of about 100 to about 2,000 feet/minute; and (ii) nomore than a total of from about 3 mg/foot²/side to about 200mg/foot²/side of the liquid lubricant is deposited on the stock sheet bythe one or more pairs of applicators.
 20. The method of claim 19,wherein one or more temperature sensing elements determine an enclosuretemperature of the enclosure and a temperature controller maintains theenclosure temperature in the range of from about 80 to 212 degreesFahrenheit and further comprising: applying air pressure to a headspaceof a lubricant-containing vessel to pneumatically cause the liquidlubricant to flow, under air pressure, to the one or more pairs ofapplicators, wherein a temperature element monitors a temperature in thelubricant-containing vessel and, in response to input from thetemperature element, a temperature controller in communication with thetemperature element causes heating of a solid lubricant in thelubricant-containing vessel; flowing the liquid lubricant from thelubricant-containing vessel to a perforated applicator element havingfirst and second perforated element surfaces, wherein the perforatedapplicator element is in fluid communication with a porous applicatorelement having first and second porous element surfaces, wherein theliquid lubricant flows from the first perforated element surface to thesecond porous element surface and from the second porous element surfaceto the first porous element surface, and wherein the contacting furthercomprises: contacting the first porous element surface with the stocksheet surface to deposit the liquid lubricant on the stock sheet; andcontrolling, in response to input from a pressure indicator, a pressureapplied to the stock sheet by the first porous element surface.
 21. Themethod of claim 19, wherein the first and second stock sheet surfacesrespectively have first and second sheet surface areas, and wherein thecontacting further comprises depositing liquid lubricant on more thanabout 99% of the first and/or second sheet surface areas.
 22. The methodof claim 19, wherein the amount of liquid lubricant deposited on thefirst and/or second stock sheet surfaces varies no more than about ±10mg/foot² and further comprising: measuring, by a first temperatureelement, a first temperature in one or more lubricant heating vessels;heating, in response to commands from a temperature controller, a solidlubricant in the one or more lubricant heating vessels to form theliquid lubricant; measuring, by a second temperature element, a secondtemperature of one or more heated transfer lines; heating, in responseto commands from the temperature controller, the one or more heatedtransfer lines; and transferring the liquid lubricant from the one ormore lubricant heating vessels to the one or more pairs of applicatorsthrough the one or more heated transfer lines.re heated transfer lines.23. The method of claim 19, wherein the passing and contacting stepscomprise: monitoring, by a first temperature element, a temperature in alubricant-containing vessel and heating, in response to input from atemperature controller in communication with the first temperatureelement, a solid lubricant in the lubricant-containing vessel to formthe liquid lubricant; monitoring, by a second temperature element, atemperature in process piping transporting the liquid lubricant from thelubricant-containing vessel to the one or more pairs of applicators; andheating, in response to input from the temperature controller incommunication with the second temperature element, the lubricant in theprocess piping, wherein prior to the contacting step, first and secondside edges of the stock sheet are substantially free of the liquidand/or the solid lubricant, and further comprising winding thelubricated stock sheet to form a coil of the lubricated stock sheet. 24.A method, comprising: heating a solid lubricant in a lubricant heatingvessel to form a liquid lubricant; transporting the liquid lubricant toa heated lubricant-containing vessel; applying pressure to a headspaceof the lubricant-containing vessel to cause pneumatically the liquidlubricant to flow under air pressure through heated piping to anenclosure comprising one or more pairs of applicators, wherein theenclosure is one or more of heated and insulated; supplying thermalenergy to the one or more pairs of applicators, wherein the thermalenergy is supplied by one or more thermal heating elements containedwithin the enclosure and positioned near each of the one or more pairsof applicators; passing a stock sheet comprising opposing substantiallyplanar first and second stock sheet surfaces joined together by opposingstock sheet side edges and opposing stock sheet ends through the sheetinlet and the sheet outlet; receiving, by a temperature controller,temperature measurements from temperature sensing elements in thermalcommunication with each of the lubricant heating vessel, heatedlubricant-containing vessel, heated piping, and one or more thermalheating elements; in response to the temperature measurements,controlling an amount of thermal energy supplied to a plurality of thelubricant heating vessel, heated lubricant-containing vessel, heatedpiping, and one or more thermal heating elements to maintain atemperature of the liquid lubricant above a melting point of the solidlubricant; and winding the lubricated stock sheet into a coil.
 25. Themethod of claim 24, wherein the melting temperature of the solidlubricant ranges from about 80 to 212 degrees Fahrenheit and furthercomprising: controlling, in response to input from a pressure indicatorand by a pressure-adjusting element, a pressure applied to the first andsecond stock sheet surfaces by the one or more pairs of applicators todeposit the liquid lubricant on the stock sheet, wherein thepressure-adjusting element comprises an electromechanical device, asolenoid, a pneumatic device, or a combination thereof.